Structural component for a modular rotor blade

- General Electric

The present disclosure is directed to a pre-formed, continuous structural component for use in assembling a modular rotor blade for a wind turbine. Further, the structural component provides support to the modular rotor blade during operation. The pre-formed structural component includes a root portion and a body portion. The root portion is configured for mounting the structural component to a blade root section of the rotor blade. The body portion is configured to extend in a generally span-wise direction. Further, the body portion defines a predetermined cross-section having a flatback portion with a first end and a second end. In addition, the first and second ends each have a flange extending perpendicularly therefrom. Thus, each flange defines a mounting surface for one or more blade segments.

Skip to: Description  ·  Claims  ·  References Cited  · Patent History  ·  Patent History
Description
FIELD OF THE INVENTION

The present disclosure relates generally to wind turbine rotor blades, and more particularly to a flatback structural component for modular wind turbine rotor blades.

BACKGROUND OF THE INVENTION

Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and a rotor having a rotatable hub with one or more rotor blades. The rotor blades capture kinetic energy of wind using known airfoil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

The rotor blades generally include a suction side shell and a pressure side shell typically formed using molding processes that are bonded together at bond lines along the leading and trailing edges of the blade. Further, the pressure and suction shells are relatively lightweight and have structural properties (e.g., stiffness, buckling resistance and strength) which are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation. Thus, to increase the stiffness, buckling resistance and strength of the rotor blade, the body shell is typically reinforced using one or more structural components (e.g. opposing spar caps with a shear web configured therebetween) that engage the inner pressure and suction side surfaces of the shell halves. The spar caps may be constructed of various materials, including but not limited to glass fiber laminate composites and/or carbon fiber laminate composites.

Such rotor blades, however, are not without issues. For example, the bond lines of typical rotor blades are generally formed by applying a suitable bonding paste or compound along the bond line with a minimum designed bond width between the shell members. These bonding lines are a critical design constraint of the blades as a significant number of turbine blade field failures occur at the bond-line. Separation of the bond line along the leading and/or trailing edges of an operational turbine blade can result in a catastrophic failure and damage to the wind turbine.

In addition, the methods used to manufacture the rotor blades and/or structural components thereof can be difficult to control, defect prone, and/or highly labor intensive due to handling of the dry fabrics and the challenges of infusing large laminated structures. Moreover, as rotor blades continue to increase in size, conventional manufacturing methods continue to increase in complexity as the blade halves are typically manufactured using opposing mold halves that must be large enough to accommodate the entire length of the rotor blade. As such, joining the large blade halves can be highly labor intensive and more susceptible to defects.

One known strategy for reducing the complexity and costs associated with pre-forming, transporting, and erecting wind turbines having rotor blades of increasing sizes is to manufacture the rotor blades in blade segments. The blade segments may then be assembled to form the rotor blade after, for example, the individual blade segments are transported to the field. However, known joint designs for connecting the blade segments together typically have a variety of disadvantages. For example, many known joint designs do not provide for sufficient alignment of the blade segments. As such, a significant amount of time is wasted in aligning the blade segments for assembly of the rotor blade. Additionally, many known joint designs include various complex interconnecting components (e.g. scarf joints), thereby increasing the amount of time needed to assemble the blade segments. In addition, segmented blades are typically heavier than blades manufactured using conventional methods due to the additional joints and/or related parts. Further, each of the segments is still manufactured using blade halves that are bonded together at leading and trailing edges, which as mentioned, is a critical design constraint.

Thus, the art is continuously seeking new and improved rotor blades and related methods that address the aforementioned issues. Accordingly, the present disclosure is directed to improved modular wind turbine rotor blades that are assembled via a flatback structural component.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one aspect, the present disclosure is directed to a modular rotor blade for a wind turbine. The rotor blade includes a pre-formed blade root section having one or more spar caps extending in a generally span-wise direction, a pre-formed blade tip section, a pre-formed structural component secured to the blade root section and extending in the span-wise direction, and a plurality of blade segments. Further, the blade segments are arranged between the blade root section and the blade tip section. Thus, the pre-formed structural component may be an internal feature configured to provide structural support to the modular rotor blade. In addition, the pre-formed structural component may be an external feature that forms a flatback cross-sectional shape of the airfoil.

In one embodiment, the pre-formed structural component may be secured to a corresponding structural component of the blade root section. More specifically, in certain embodiments, the structural component may further include a root portion and a body portion. Thus, in particular embodiments, the root portion may be secured to the corresponding structural component of the blade root section, e.g. via a scarf joint. In another embodiment, the corresponding structural component of the blade root section may have a cross-section that varies with a cross-sectional shape of the blade root section. In certain embodiments, the structural component may be configured at a location of within 50% chord from a trailing edge of the rotor blade.

In additional embodiments, the structural component may be constructed of one or more pultruded parts. Thus, in certain embodiments, the structural component may have a constant cross-section from a root to a tip of the structural component. In alternative embodiments, the structural component may have a varying cross-section along a length thereof. For example, in particular embodiments, the cross-section of the structural component may include a flatback portion having a first end and a second end. In addition, the first and second ends may each include a flange extending perpendicularly therefrom. Thus, the flanges provide a mounting surface for the blade segment(s) described herein. In yet another embodiment, the structural component may be constructed of any suitable materials, including but not limited to thermoset polymer, a thermoplastic polymer, or similar.

In additional embodiment, the blade segment(s) as described herein may include leading or trailing edge segments, pressure or suction side segments, non-jointed, continuous blade segments, single-jointed blade segments, forward pressure side segments, forward suction side segments, aft pressure side segments, aft suction side segments, or similar or any combinations thereof.

In yet another embodiment, the blade root section and/or the blade tip section may include one or more spar caps extending therefrom. Thus, in certain embodiments, the blade root section and the blade tip section may be joined together via their respective spar cap(s).

In another aspect, the present disclosure is directed to a pre-formed structural component for use in assembling a modular rotor blade for a wind turbine. The pre-formed structural component includes a root portion configured for mounting to a blade root section of the rotor blade and a body portion configured to extend in a generally span-wise direction. Further, the body portion defines a cross-section having a flatback portion with a first end and a second end. In addition, the first and second ends each have a flange extending perpendicularly therefrom. Thus, each flange defines a mounting surface for one or more blade segments.

In yet another aspect, the present disclosure is directed to a method for assembling a modular rotor blade for a wind turbine. The method includes providing a pre-formed blade root section and a pre-formed blade tip section for the rotor blade. Another step includes pre-forming a continuous structural component of the rotor blade. The method also includes providing one or more pre-formed blade segments of the rotor blade. A further step includes securing the structural component to the blade root section such that the structural component extends in a generally span-wise direction. Thus, the method also includes mounting the one or more blade segments to the structural component between the blade root section and the blade tip section.

In one embodiment, the blade segment(s) may include at least one leading edge segment and at least one trailing edge segment. In such embodiments, the method may also include mounting one or more trailing edge segments to the structural component between the blade root section and the blade tip section in a generally span-wise direction, and securing one or more leading edge segments to the mounted trailing edge segment at a pressure side seam and a suction side seam such that the structural component is within the one or more leading and trailing edge segments. In alternative embodiments, the method may include mounting one or more blade segments to the structural component between the blade root section and the blade tip section in a generally span-wise direction such that the structural component is external to the one or more blade segments. The blade segment(s) described herein may also include pressure or suction side segments, a non-jointed, continuous blade segment, a single-jointed blade segment, a forward pressure side segment, a forward suction side segment, an aft pressure side segment, an aft suction side segment, or similar or any combinations thereof.

In another embodiment, the method may also include securing the pre-formed continuous structural component to a corresponding structural component of the blade root section. Further, in particular embodiments, the method may further include securing a root portion of the pre-formed structural component to the corresponding structural component of the blade root section, e.g. via a scarf joint. In particular embodiments, the method may also include pre-forming the corresponding structural component of the blade root section so as to have a cross-section that varies with a cross-sectional shape of the blade root section.

In additional embodiments, the step of pre-forming the structural component may include utilizing at least one of pultrusion, vacuum infusion, resin transfer molding (RTM), light resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), a forming process (e.g. thermoforming), or similar. For example, in certain embodiments, the pultruded structural component may have a cross-section that varies along a length thereof (e.g. from a root to a tip of the structural component). Alternatively, the cross-section may be constant along a length thereof. More specifically, the cross-section may include a flatback portion with a first end and a second end. Further, the first and second ends may each include a flange extending perpendicularly therefrom. Thus, the flanges are configured to provide a mounting surface for the various blade components, e.g. the blade segments. Accordingly, in certain embodiments, the method may also include mounting the one or more blade segments to the flanges of the structural component.

In still further embodiments, the method may also include co-infusing one or more spar caps with at least one of the blade root section or the blade tip section. In such an embodiment, the method may further include joining the blade root section and the blade tip section via their respective spar caps.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 illustrates a perspective view of one embodiment of a wind turbine according to the present disclosure;

FIG. 2 illustrates a perspective view of one embodiment of a modular rotor blade of a wind turbine according to the present disclosure;

FIG. 3 illustrates an exploded view of the modular rotor blade of FIG. 2;

FIG. 4 illustrates a cross-sectional view of one embodiment of a leading edge segment of a modular rotor blade according to the present disclosure;

FIG. 5 illustrates a cross-sectional view of one embodiment of a trailing edge segment of a modular rotor blade according to the present disclosure;

FIG. 6 illustrates a cross-sectional view of the modular rotor blade of FIG. 2 along line 6-6;

FIG. 7 illustrates a cross-sectional view of the modular rotor blade of FIG. 2 along line 7-7;

FIG. 8 illustrates a cross-sectional view of another embodiment of a modular rotor blade according to the present disclosure, particularly illustrating overlapping pressure and suction side seams;

FIG. 9 illustrates a cross-sectional view of another embodiment of a modular rotor blade according to the present disclosure, particularly illustrating a non-jointed, continuous blade segment;

FIG. 10 illustrates a cross-sectional view of another embodiment of a modular rotor blade according to the present disclosure, particularly illustrating a single-jointed blade segment;

FIG. 11 illustrates a cross-sectional view of another embodiment of a modular rotor blade according to the present disclosure, particularly illustrating a plurality of blade segments joined together via multiple joints;

FIG. 12 illustrates a side view of one embodiment of a modular rotor blade, particularly illustrating a structural component configured with a corresponding structural component of a blade root section of the rotor blade according to the present disclosure;

FIG. 13 illustrates a side view of another embodiment of a modular rotor blade, particularly illustrating a structural component configured with a blade root section of the rotor blade according to the present disclosure;

FIG. 14 illustrates an end view of one embodiment of a modular rotor blade, particularly illustrating a structural component configured with a corresponding structural component of a blade root section of the rotor blade according to the present disclosure;

FIG. 15 illustrates a cross-sectional view of the modular rotor blade of FIG. 14 along line 15-15;

FIG. 16 illustrates a detailed end view of the embodiment of FIG. 10;

FIG. 17 illustrates a detailed side view of the embodiment of FIG. 10;

FIG. 18 illustrates a detailed side view as viewed from a trailing edge of the rotor blade of the embodiment of FIG. 10; and

FIG. 19 illustrates a flow diagram of a method for assembling a modular rotor blade for a wind turbine according to the present disclosure.

 DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Generally, the present disclosure is directed to a pre-formed, continuous structural component for use in assembling a modular rotor blade for a wind turbine. The pre-formed structural component includes a root portion that is mounted to a blade root section of the rotor blade and a body portion configured to extend in a generally span-wise direction. Further, the body portion defines a cross-section having a flatback portion with a first end and a second end. In addition, the first and second ends each have a flange extending perpendicularly therefrom so as to define a mounting surface for one or more modular blade segments that form the outer covering of the rotor blade.

Thus, the present disclosure provides many advantages not present in the prior art. For example, the continuous structural component of the present disclosure provides a mounting surface for the blade segments, thereby eliminating the need for complex scarf joints between segments. Further, the flanges on the flatback portion improve buckling resistance in the blade segments. As such, the present disclosure provides improved modular rotor blades that may increase supply chain options, reduce manufacturing cycle time, and/or reduce shipping cost. Thus, the rotor blades and methods of the present disclosure provide an economic alternative to conventional rotor blades. Further, the modular rotor blades of the present disclosure have a reduced weight.

Referring now to the drawings, FIG. 1 illustrates one embodiment of a wind turbine 10 according to the present disclosure. As shown, the wind turbine 10 includes a tower 12 with a nacelle 14 mounted thereon. A plurality of rotor blades 16 are mounted to a rotor hub 18, which is in turn connected to a main flange that turns a main rotor shaft. The wind turbine power generation and control components are housed within the nacelle 14. The view of FIG. 1 is provided for illustrative purposes only to place the present invention in an exemplary field of use. It should be appreciated that the invention is not limited to any particular type of wind turbine configuration. In addition, the present invention is not limited to use with wind turbines, but may be utilized in any application having rotor blades.

Referring now to FIGS. 2 and 3, various views of a modular rotor blade 16 manufactured according to the present disclosure are illustrated. As shown, the rotor blade 16 includes a modular configuration having a pre-formed blade root section 20, a pre-formed blade tip section 22 disposed opposite the blade root section 20, and a plurality of blade segments arranged therebetween. The blade root section 20 is configured to be mounted or otherwise secured to the rotor 18 (FIG. 1). Further, as shown in FIG. 2, the rotor blade 16 defines a span 23 that is equal to the total length between the blade root section 20 and the blade tip section 22. In addition, as shown in FIGS. 2 and 6, the rotor blade 16 defines a chord 25 that is equal to the total length between a leading edge 40 of the rotor blade 16 and a trailing edge 42 of the rotor blade 16. As is generally understood, the chord 25 may generally vary in length with respect to the span 23 as the rotor blade 16 extends from the blade root section 20 to the blade tip section 22.

In addition, as shown in the illustrated embodiment, the blade segments generally serve as the outer casing/covering of the rotor blade 16 and may define a substantially aerodynamic profile, such as by defining a symmetrical or cambered airfoil-shaped cross-section. Further, as shown, the blade segment(s) may include a plurality of leading edge segments 24 and a plurality of trailing edge segments 26 generally arranged between the blade root section 20 and the blade tip section 22 along a longitudinal axis 27 in a generally span-wise direction. In additional embodiments, it should be understood that the blade segment portion of the blade 16 may include any combination of the segments described herein and are not limited to the embodiment as depicted.

Referring now to FIG. 4, each of the leading edge segments 24 has a forward pressure side surface 28 and a forward suction side surface 30. Similarly, as shown in FIG. 5, each of the trailing edge segments 26 has an aft pressure side surface 32 and an aft suction side surface 34. In addition, as particularly shown in FIG. 6, the leading edge segment(s) 26 and the trailing edge segment(s) 26 may be joined at a pressure side seam 36 and a suction side seam 38. Thus, the forward pressure side surface 28 of the leading edge segment 24 and the aft pressure side surface 32 of the trailing edge segment 26 generally define a pressure side surface of the rotor blade 16. Similarly, the forward suction side surface 30 of the leading edge segment 24 and the aft suction side surface 34 of the trailing edge segment 26 generally define a suction side surface of the rotor blade 16.

In further embodiments, as shown in FIG. 8, the leading edge segment(s) 24 and the trailing edge segment(s) 26 may be configured to overlap at the pressure side seam 36 and/or the suction side seam 38. In addition, as shown in FIG. 2, adjacent leading edge segments 24 as well as adjacent trailing edge segments 26 may be configured to overlap at a seam 54. More specifically, in certain embodiments, the various segments of the rotor blade 16 may be further secured together, e.g. via an adhesive 56 configured between the overlapping leading and trailing edge segments 24, 26 and/or the overlapping adjacent leading or trailing edge segments 24, 26.

In addition, the pressure side seam 26 and/or the suction side seam 38 may be located at any suitable chord-wise location. For example, as shown in FIGS. 6 and 8, the seams 36, 38 may be located from about 40% to about 60% chord from the leading edge 40 of the rotor blade 16. More specifically, in certain embodiments, the seams 36, 38 may be located at about 50% chord from the leading edge 40. In still further embodiments, the seams 36, 38 may be located less than 40% chord or greater than 60% chord from the leading edge 40 of the rotor blade 16. In addition, in some embodiments, the seams 36, 38 may be aligned as generally shown in the figures. Alternatively, the seams 36, 38 may be offset.

In additional embodiments, as shown in FIGS. 2-3 and 7, the rotor blade 16 may also include at least one pressure side segment 44 and/or at least one suction side segment 46. For example, as shown in FIG. 7, the rotor blade 16 may include a pressure side segment 44 arranged and joined with a suction side segment 46 at the leading and trailing edges 40, 42. Such segments may be used in combination with and/or exclusive of the additional segments as described herein.

Thus far, the segments described herein are joined at two joint locations. Although, in further embodiments, less than two or more than two joint locations may be utilized. For example, as shown in FIG. 9, the rotor blade 16 may also include non-jointed, continuous blade segments 45. More specifically, as shown, the non-jointed, continuous blade segment 45 does not require bonding of multiple segments. Such segments 45 may be used in combination with and/or exclusive of the additional segments as described herein. Further, as shown in FIG. 10, the rotor blade 16 may also include a single-jointed blade segment 55. More specifically, as shown, the blade segment 55 may include a pressure side surface 33, a suction side surface 31, and a single joint 57 at the trailing edge 42. Thus, the blade segment 55 only requires one joint instead of multiple joints. Such segments 55 may be used in combination with and/or exclusive of the additional segments as described herein. Moreover, as shown in FIG. 11, the rotor blade 16 may also include a multi jointed blade segment 59. More specifically, as shown, the blade segment 59 includes a plurality of segments 41, 43, 47, 49 joined together via multiple joints 61, 63, 65, 67 spaced about the cross-section of the blade segment 59. More specifically, the blade segments 41, 43, 47, 49 may include a forward pressure side segment 43, a forward suction side segment 41, an aft pressure side segment 49, and an aft suction side segment 47. Such segments may be used in combination with and/or exclusive of the additional segments as described herein.

Referring now to FIGS. 2-3 and 6-7, the rotor blade 16 may also include one or more longitudinally extending spar caps configured to provide increased stiffness, buckling resistance and/or strength to the rotor blade 16. For example, the blade root section 20 may include one or more longitudinally extending spar caps 48, 50 configured to be engaged against the opposing inner surfaces of the leading and trailing edge segments 24, 26 of the rotor blade 16. Similarly, the blade tip section 22 may include one or more longitudinally extending spar caps 51, 53 configured to be engaged against the opposing inner surfaces of the leading and trailing edge segments 24, 26 of the rotor blade 16. In addition, blade tip section 20 and/or the blade root section 22 may also include one or more shear webs 35 configured between the one or more spar caps 48, 50, 51, 53 of the blade root section 20 or the blade tip section 22, respectively. As such, the shear web(s) 35 are configured to increase the rigidity in the blade root section 20 and/or the blade tip section 22, thereby allowing the sections 20, 22 to be handled with more control.

More specifically, in particular embodiments, the blade root section 20 and/or the blade tip section 22 may be pre-formed with the one or more spar caps 48, 50, 51, 53. Further, the blade root spar caps 48, 50 may be configured to align with the blade tip spar caps 51, 53. Thus, the spar caps 48, 50, 51, 53 may generally be designed to control the bending stresses and/or other loads acting on the rotor blade 16 in a generally span-wise direction (a direction parallel to the span 23 of the rotor blade 16) during operation of a wind turbine 10. In addition, the spar caps 48, 50, 51, 53 may be designed to withstand the span-wise compression occurring during operation of the wind turbine 10. Further, the spar cap(s) 48, 50, 51, 53 may be configured to extend from the blade root section 20 to the blade tip section 22 or a portion thereof. Thus, in certain embodiments, the blade root section 20 and the blade tip section 22 may be joined together via their respective spar caps 48, 50, 51, 53.

In further embodiments, as shown in FIGS. 2, 3, and 12-18, the rotor blade 16 may also include a pre-formed, continuous structural component 52 secured to the blade root section 20. Thus, as shown, the structural component 52 is configured to extend in a generally span-wise direction. More specifically, the structural component 52 may extend any suitable distance between the blade root section 20 and the blade tip section 22. As such, the structural component 52 is configured to provide additional structural support for the rotor blade 16 as well as a mounting structure for the various blade segments as described herein. For example, in certain embodiments, the structural component 52 may be secured to the blade root section 20 and may extend a predetermined span-wise distance such that the leading and/or trailing edge segments 24, 26 can be mounted thereto.

In certain embodiments, as shown in FIGS. 12-14 and 17-19, the pre-formed structural component 52 may be secured to a corresponding structural component 58 of the blade root section 20. More specifically, as shown particularly in FIGS. 17 and 18, the structural component 52 may further include a root portion 60 and a body portion 62. As such, in certain embodiments, the root portion 60 may be secured to the corresponding structural component 58 of the blade root section 20, e.g. via a scarf joint, as shown in FIGS. 12 and 13. Thus, in certain embodiments, as shown in FIG. 12, the pre-formed structural component 52 may be an internal feature configured to provide structural support to the modular rotor blade 16. In additional embodiments, as shown in FIG. 13, the pre-formed structural component 52 may be an external feature of the blade root section 20 that forms a flatback cross-sectional shape of the airfoil.

In additional embodiments, the structural component 52 may be constructed of one or more pultruded parts. As used herein, the terms “pultruded parts,” “pultrusions,” or similar generally encompass reinforced materials (e.g. fibers or woven or braided strands) that are impregnated with a resin and pulled through a stationary die such that the resin cures or undergoes polymerization. As such, the process of manufacturing pultruded parts is typically characterized by a continuous process of composite materials that produces composite parts having a constant cross-section. Alternatively, the structural component 52 may be constructed of a core material and one or more skin layers (e.g. a combination of biaxial and unidirectional glass fiber reinforced resin). Thus, in certain embodiments, the structural component 52 may be constructed using a resin infusion process. Further, it should be understood that the structural component 52 may be constructed of any suitable materials. For example, in certain embodiments, the structural component 52 may be constructed of a thermoset polymer, a thermoplastic polymer, or similar.

Accordingly, it should be understood that the structural component 52 may have any suitable cross-sectional shape (that varies or is constant) along a length thereof (e.g. from a root 63 to a tip 65 of the structural component 52). For example, as shown in FIG. 15, the cross-section of the structural component 52 may have a substantially C-shaped configuration. More specifically, as shown, the cross-section may have a flatback portion 64 with a first end 66 and a second end 68. In addition, the first and second ends 66, 68 may each include a flange 70, 72 extending perpendicularly therefrom. As such, the flanges 70, 72 may be configured as suitable mounting structures for the blade segments as described herein. In additional embodiments, the cross-section of the structural component 52 may further include an I-shaped configuration. In further embodiments, as shown in FIGS. 16-18, the corresponding structural component 58 of the blade root section 20 may have a cross-section that varies with a cross-sectional shape of the blade root section 20.

The flanges 70, 72 of the structural component 52 described herein may be constructed using any suitable means. For example, in certain embodiments, the flanges 70, 72 may be pultruded. In additional embodiments, the flanges 70, 72 may be constructed using dry fabric infusion, belt pressing techniques, or similar.

Referring now to FIG. 19, a flow diagram of a method 100 for assembling a modular rotor blade 16 for a wind turbine 10 using the structural component 52 as described herein is illustrated. As shown at 102, the method 100 includes providing a pre-formed blade root section 20 and a pre-formed blade tip section 22 of the rotor blade 16. As shown at 104, the method 100 includes pre-forming a continuous structural component 52 of the rotor blade 16. For example, in one embodiment, the method 100 may include pre-forming the structural component 52 via at least one of pultrusion, vacuum infusion, resin transfer molding (RTM), light resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), a forming process (e.g. thermoforming), or similar.

In certain embodiments, the method 100 may also include pre-forming the structural component 52 with one or more pultruded parts. In addition, the method 100 may include pre-forming the structural component 52 such that the component has a predetermined cross-section. For example, as shown in FIG. 15, the predetermined cross-section of the structural component 52 may include a flatback portion 64 having first and second ends 66, 68, with each end including a flange 70, 72 extending perpendicularly therefrom. In addition, as shown, the structural component 52 may be configured at a location of within 50% chord from a trailing edge of the rotor blade 16. As such, the structural component 52 is located closer to the trailing edge 42 than the leading edge 40.

As shown at 106, the method 100 may also include providing one or more pre-formed blade segments. For example, in certain embodiments, the blade segment(s) may be pre-formed using any combination of materials and methods now known or later developed in the art. In addition, it should be understood that the blade segment(s) may include any suitable combination of segments as described herein that form an airfoil. For example, the blade segment(s) may include leading or trailing edge segments 24, 26, pressure or suction side segments 44, 46, a non jointed airfoil segment, a single-jointed blade segment, a multi jointed blade segment, or any combinations thereof.

As shown at 108, the method 100 may also include securing the structural component 52 to the blade root section 20 such that the structural component extends in a generally span-wise direction. For example, in one embodiment, the method 100 may also include securing the pre-formed structural component 52 to a corresponding structural component 58 of the blade root section 20. Further, in particular embodiments, the method 100 may further include securing a root portion 60 of the pre-formed structural component 52 to the corresponding structural component 58 of the blade root section 20 via a scarf joint.

As shown at 110, the method 100 also includes mounting the blade segment(s) to the structural component 52 between the blade root section 20 and the blade tip section 22. More specifically, in certain embodiments, the method 100 may also include mounting the blade segment(s) to the flanges 70, 72 of the structural component 52. For example, in certain embodiments, the method 100 may include mounting pre-formed leading and trailing edge segments 24 to the structural component 52 between the blade root section 20 and the blade tip section. In additional embodiments, the method 100 may further include mounting at least one pressure side segment 44 and at least one suction side segment 46 to the structural component 52 between the blade root section 20 and the blade tip section 22 in a generally span-wise direction.

In further embodiments, the method 100 may also include pre-forming the corresponding structural component 58 of the blade root section 20 so as to have a cross-section that varies with a cross-sectional shape of the blade root section 20.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A modular rotor blade for a wind turbine, the rotor blade comprising:

a pre-formed blade root section comprising one or more spar caps extending in a generally span-wise direction, the blade root section comprising a leading edge and a trailing edge;
a pre-formed blade tip section;
a continuous, pre-formed structural component secured to and extending at least partially through the blade root section in the span-wise direction, the pre-formed structural component comprising a root portion and a body portion, the body portion of the pre-formed structural component defining a substantially U-shaped cross-section defining a flatback portion and integral opposing flange portions extending from opposite ends of the flatback portion, the pre-formed structural component formed of a thermoplastic material;
a corresponding structural component secured to the root portion of the pre-formed structural component within the blade root section and aligned with the pre-formed structural component in the span-wise direction, the corresponding structural component extending in the span-wise direction from a root end to a tip end, the corresponding structural component terminating at the root end and the tip end, the root end defining a maximum, first height that tapers to a lesser, second height of the pre-formed structural component, the corresponding structural component of the blade root section located at the trailing edge of the blade root section and following a contour of the trailing edge of the blade root section; and,
one or more blade segments arranged between the blade root section and the blade tip section, wherein at least one of the one or more blade segments is mounted to the flange portions of the pre-formed structural component.

2. The rotor blade of claim 1, wherein the root portion of the structural component is secured to the corresponding structural component of the blade root section via a scarf joint.

3. The rotor blade of claim 2, wherein the corresponding structural component of the blade root section comprises a cross-section that varies with a cross-sectional shape of the blade root section.

4. The rotor blade of claim 1, wherein the pre-formed structural component is positioned at a location of within 50% chord from a trailing edge of the rotor blade.

5. The rotor blade of claim 1, wherein the pre-formed structural component is constructed of one or more pultruded parts.

6. The rotor blade of claim 1, wherein the pre-formed structural component comprises a constant cross-section along a length thereof.

7. The rotor blade of claim 1, wherein the pre-formed structural component comprises a varying cross-section along a length thereof.

8. The rotor blade of claim 1, wherein the blade tip section comprises one or more spar caps, wherein the blade root section and the blade tip section are joined together via their respective spar caps.

9. A method for assembling a modular rotor blade for a wind turbine, the method comprising:

providing a pre-formed blade root section and a pre-formed blade tip section of the rotor blade, the blade root section comprising a leading edge and a trailing edge;
pultruding a continuous structural component for the rotor blade of a thermoplastic material, the pultruded structural component having a root portion and a body portion, the body portion having a substantially U-shaped cross-section comprising a flatback portion and integral opposing flange portions extending from opposite ends of the flatback portion;
securing a corresponding structural component to the blade root section at the trailing edge thereof, the corresponding structural component following a contour of the trailing edge of the blade root section, the corresponding structural component extending from a root end to a tip end, the corresponding structural component terminating at the root end and the tip end;
securing the pultruded structural component to the corresponding structural component within the blade root section such that the pultruded structural component and the corresponding structural component extend in a span-wise direction, the root end of the corresponding structural component defining a maximum, first height that tapers to a lesser, second height of the pre-formed structural component; and,
mounting one or more blade segments to the flange portions of the pultruded structural component between the blade root section and the blade tip section.

10. The method of claim 9, wherein the one or more blade segments comprise at least one of a leading edge segment, a trailing edge segment, a pressure side segment, a suction side segment, a non-jointed, continuous blade segment, a single-jointed blade segment, a forward pressure side segment, a forward suction side segment, an aft pressure side segment, or an aft suction side segment.

11. The method of claim 10, further comprising:

mounting one or more trailing edge segments to the pultruded structural component between the blade root section and the blade tip section in the generally span-wise direction, and
securing one or more leading edge segments to the mounted one or more trailing edge segments at a pressure side seam and a suction side seam such that the pultruded structural component is within the one or more leading and trailing edge segments.

12. The method of claim 9, further comprising mounting one or more blade segments to the pultruded structural component between the blade root section and the blade tip section in the generally span-wise direction such that the pultruded structural component is external to the one or more blade segments.

13. The method of claim 9, further comprising securing the root portion of the pultruded structural component to the corresponding structural component of the blade root section via a scarf joint.

14. The method of claim 13, further comprising pre-forming the corresponding structural component of the blade root section so as to have a cross-section that varies with a cross-sectional shape of the blade root section.

Referenced Cited
U.S. Patent Documents
2884078 April 1959 Stamm et al.
4329119 May 11, 1982 Baskin
4474536 October 2, 1984 Gougeon et al.
5476704 December 19, 1995 Köhler
6264877 July 24, 2001 Pallu De La Barriere
7473385 January 6, 2009 Stiesdal et al.
7503752 March 17, 2009 Gunneskov et al.
7625185 December 1, 2009 Wobben
7637721 December 29, 2009 Driver et al.
7654799 February 2, 2010 Eyb
7854594 December 21, 2010 Judge
7922454 April 12, 2011 Riddell
8043065 October 25, 2011 Kyriakides
8057189 November 15, 2011 Riahi
8079818 December 20, 2011 Burchardt et al.
8114329 February 14, 2012 Karem
8142162 March 27, 2012 Godsk et al.
8147209 April 3, 2012 Godsk et al.
8168027 May 1, 2012 Jacobsen et al.
8172538 May 8, 2012 Hancock et al.
8262361 September 11, 2012 Sanz Pascual et al.
8297932 October 30, 2012 Arocena De La Rua et al.
8297933 October 30, 2012 Riahi
8317479 November 27, 2012 Vronsky et al.
8348622 January 8, 2013 Bech
8353674 January 15, 2013 Bech
8455090 June 4, 2013 Schmidt et al.
8506258 August 13, 2013 Baker et al.
8511996 August 20, 2013 Llorente Gonzalez et al.
8517689 August 27, 2013 Kyriakides et al.
8540491 September 24, 2013 Gruhn et al.
8545744 October 1, 2013 Jones
8580060 November 12, 2013 Bech
8657581 February 25, 2014 Pilpel et al.
8673106 March 18, 2014 Jolley et al.
8696317 April 15, 2014 Rudling
8747098 June 10, 2014 Johnson et al.
8764401 July 1, 2014 Hayden et al.
8826534 September 9, 2014 Cappelli et al.
8827655 September 9, 2014 Bech
8894374 November 25, 2014 Fuglsang et al.
8918997 December 30, 2014 Kyriakides et al.
8961142 February 24, 2015 Wansink
8992813 March 31, 2015 Robbins et al.
20070036659 February 15, 2007 Hibbard
20090148300 June 11, 2009 Driver et al.
20100098549 April 22, 2010 Mironov
20100303631 December 2, 2010 Payne
20110031758 February 10, 2011 Mitsuoka et al.
20110037191 February 17, 2011 Stiesdal
20110045276 February 24, 2011 Grove-Nielsen
20110081248 April 7, 2011 Hibbard
20110103962 May 5, 2011 Hayden et al.
20110114252 May 19, 2011 Partington et al.
20110142662 June 16, 2011 Fritz et al.
20110142670 June 16, 2011 Pilpel
20110206529 August 25, 2011 Bell
20110318186 December 29, 2011 Kristensen et al.
20120034096 February 9, 2012 Appleton
20120039720 February 16, 2012 Bech
20120180582 July 19, 2012 Piasecki
20120183408 July 19, 2012 Noerlem
20120230830 September 13, 2012 Lind et al.
20120237356 September 20, 2012 Mironov
20120257984 October 11, 2012 Frederiksen
20130012086 January 10, 2013 Jones et al.
20130022466 January 24, 2013 Laurberg
20130108453 May 2, 2013 Baker et al.
20130149166 June 13, 2013 Schibsbye
20130164133 June 27, 2013 Grove-Nielsen
20130195661 August 1, 2013 Lind et al.
20130231018 September 5, 2013 Kruger et al.
20130333823 December 19, 2013 Hedges et al.
20140003955 January 2, 2014 Richter
20140003956 January 2, 2014 Lull et al.
20140023513 January 23, 2014 Johnson et al.
20140030094 January 30, 2014 Dahl et al.
20140119936 May 1, 2014 Dahl et al.
20140140855 May 22, 2014 Arendt et al.
20140271217 September 18, 2014 Baker
20140295187 October 2, 2014 Jacobsen et al.
20140348659 November 27, 2014 Stewart
20150003991 January 1, 2015 Bagepalli et al.
20150224760 August 13, 2015 Eyb et al.
20150316023 November 5, 2015 Sandercock
20150316028 November 5, 2015 Brekenfeld
Foreign Patent Documents
2011304537 March 2012 AU
2517951 September 2004 CA
2526407 December 2004 CA
201155423 November 2008 CN
100476200 April 2009 CN
101302302 February 2011 CN
102705157 October 2012 CN
101906251 June 2013 CN
102011051172 December 2012 DE
102012019351 April 2014 DE
201270816 January 2014 DK
201270818 January 2014 DK
2113373 January 2011 EP
2255957 July 2013 EP
2617558 July 2013 EP
2679804 January 2014 EP
2679806 January 2014 EP
2682256 January 2014 EP
2687557 January 2014 EP
2455419 March 2014 EP
1808598 April 2014 EP
2752577 July 2014 EP
2451192 January 2009 GB
2455044 June 2009 GB
2464539 April 2010 GB
2485453 May 2012 GB
2520007 May 2015 GB
2002137307 May 2002 JP
2007092716 April 2007 JP
3930200 June 2007 JP
2009235306 October 2009 JP
2014015567 January 2014 JP
5439412 March 2014 JP
W003082551 October 2003 WO
WO 2007/051465 May 2007 WO
WO 2008/086805 July 2008 WO
WO 2009/118545 October 2009 WO
WO 2010/025830 March 2010 WO
WO 2010/057502 May 2010 WO
WO 2010/083921 July 2010 WO
2011088834 July 2011 WO
WO 2011/088835 July 2011 WO
WO 2011/098785 August 2011 WO
WO 2011/113812 September 2011 WO
WO 2012/010293 January 2012 WO
WO 2012/042261 April 2012 WO
WO 2012/140039 October 2012 WO
WO 2012/161741 November 2012 WO
WO 2013/007351 January 2013 WO
WO 2013/060582 May 2013 WO
WO 2013/087078 June 2013 WO
WO 2013/091639 June 2013 WO
WO 2013/178228 December 2013 WO
WO 2014/001537 January 2014 WO
WO 2014/044280 March 2014 WO
WO 2014/063944 May 2014 WO
WO 2014/079456 May 2014 WO
WO 2014/079565 May 2014 WO
WO 2015/015202 May 2014 WO
Other references
  • European Search Report and Opinion issued in connection with corresponding European Application No. 16176516.9 dated Nov. 23, 2016.
  • Co pending U.S. Appl. No. 14/188,356, filed Feb. 25, 2014.
Patent History
Patent number: 10337490
Type: Grant
Filed: Jun 29, 2015
Date of Patent: Jul 2, 2019
Patent Publication Number: 20160377051
Assignee: General Electric Company (Schenectady, NY)
Inventors: Christopher Daniel Caruso (Greenville, SC), Aaron A. Yarbrough (Clemson, SC), Daniel Alan Hynum (Simpsonville, SC)
Primary Examiner: Christopher Verdier
Assistant Examiner: Jason G Davis
Application Number: 14/753,150
Classifications
Current U.S. Class: 416/223.0R
International Classification: F03D 1/06 (20060101); F03D 13/10 (20160101); B29D 99/00 (20100101); B29K 101/12 (20060101); B29K 101/10 (20060101);